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CA1322088C - Method and apparatus for preparing textured apertured film - Google Patents

Method and apparatus for preparing textured apertured film

Info

Publication number
CA1322088C
CA1322088C CA000576297A CA576297A CA1322088C CA 1322088 C CA1322088 C CA 1322088C CA 000576297 A CA000576297 A CA 000576297A CA 576297 A CA576297 A CA 576297A CA 1322088 C CA1322088 C CA 1322088C
Authority
CA
Canada
Prior art keywords
film
embossing
roll
macro
micro
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000576297A
Other languages
French (fr)
Inventor
Alex W. Cabe, Jr.
Arthur J. Sampson
Robert W. Saffel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Chicopee Inc
Original Assignee
Chicopee Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Chicopee Inc filed Critical Chicopee Inc
Application granted granted Critical
Publication of CA1322088C publication Critical patent/CA1322088C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/512Topsheet, i.e. the permeable cover or layer facing the skin characterised by its apertures, e.g. perforations
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577Apparatus or processes for manufacturing
    • A61F13/15707Mechanical treatment, e.g. notching, twisting, compressing, shaping
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/51104Topsheet, i.e. the permeable cover or layer facing the skin the top sheet having a three-dimensional cross-section, e.g. corrugations, embossments, recesses or projections
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/51121Topsheet, i.e. the permeable cover or layer facing the skin characterised by the material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/022Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31FMECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/07Embossing, i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profiles
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F2013/51078Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers being embossed
    • A61F2013/5108Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers being embossed in grids
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F2013/51078Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers being embossed
    • A61F2013/51088Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers being embossed in very fine microtexture
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/513Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability
    • A61F2013/51338Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability having improved touch or feeling, e.g. smooth film
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/022Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
    • B29C2059/023Microembossing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00Shaping characteristics in general
    • B29C2791/001Shaping in several steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31FMECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07Embossing
    • B31F2201/0707Embossing by tools working continuously
    • B31F2201/0715The tools being rollers
    • B31F2201/0723Characteristics of the rollers
    • B31F2201/0725Hardness
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31FMECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07Embossing
    • B31F2201/0707Embossing by tools working continuously
    • B31F2201/0715The tools being rollers
    • B31F2201/0723Characteristics of the rollers
    • B31F2201/0733Pattern
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31FMECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07Embossing
    • B31F2201/0707Embossing by tools working continuously
    • B31F2201/0715The tools being rollers
    • B31F2201/0723Characteristics of the rollers
    • B31F2201/0738Cross sectional profile of the embossments
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31FMECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07Embossing
    • B31F2201/0758Characteristics of the embossed product
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31FMECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07Embossing
    • B31F2201/0771Other aspects of the embossing operations
    • B31F2201/0774Multiple successive embossing operations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31FMECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07Embossing
    • B31F2201/0784Auxiliary operations
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness

Landscapes

  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Vascular Medicine (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • Epidemiology (AREA)
  • Biomedical Technology (AREA)
  • Veterinary Medicine (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Molding Of Porous Articles (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Shaping By String And By Release Of Stress In Plastics And The Like (AREA)

Abstract

ABSTRACT

Apertured polymeric films for use as a liquid permeable facing material on absorbent products such as diapers and sanitary napkins is textured by a dual embossing process. The film is preferably embossed first with a pronounced, textile-like pattern, then embossed with a finely engraved finish roll to produce a thin, smooth film with a matte finish while retaining the appearance of the previously embossed pattern. The twice embossed film is soft, conformable, and more comfortable against the skin. The embossing sequence may be reversed for some applications.

Description

~ 322~38 METHOD AND APPARATUS FOR PREPARING TEXTURED APERTlJRED FILM

E~ield of the Invention This invention relates to apertured plastic films for use in absorbent products and, more specifically, to a method and apparatus for imparting a desirable appearance and texture to such film.

10 Backaround Absorbent products such as diapers, sanitary napkins and the like generally include a liquid permeable cover on one surface which may be fabric or apertured film. The purpose of the cover is to structurally contain the loosely packed absorbent material which comprises the bul~ of the absorbent product, and to protect the body from direct contact with the absorbent material. The cover is preferably nonabsorbent so that the surface of the cover maintains a dry feel while fluids pass through the cover into the absorbent core. Since the cover material is in direct contact with the body, it should be smooth, soft and comfortable to the touch. Certain visual characteris~ics such as color, lustre, and texture are also important to consumer acceptance and satisfaction.
Apertured films of polypropylene and polyethylene have been widely used as cover materials for absorbent products since these films are inexpensive, nonabsorbent and readily produced. A particularly preferred material for use as a cover is a coextruded film of polyethylene and ethylene vinyl acetate (EYA) as described in U.S. Patent No.4,690,679. The polyethylene side of the film which is used as the body contact side, has a higher melting point than the EVA side of the film which permits the film to be thermally bonded while maintaining structural integrity. The outer polyethylene component of the film may be delustred with calcium carbonate while the EVA
component may be pigmented with TiO2 to increase the opacity of the film.

The polyethylene, coextruded polyethylene/EVA or other polymeric film is impervious to liquids as produced, and must be perforated or otherwise apertured for use as a liquid permeable cover material. The film may be perforated by known methods such as needle punching, pin perforating, embossing and stretching, or roll forming as disclosed in U.S. Patent ~o.
4,690,679. Alternatively, the film may be extruded with a solid particulate component which is subsequently removed from the film by stretching and/or mechanical or chemical means.
These and other methods may be utilized to produce an apertured, liguid permeable film for use as a cover material on absorbent products.

Apertured films as produced by the aforementioned methods have the desired liquid permeability and other functional properties, but are often lacking in aesthetics. In particular, these films may retain the Hplastic" feel characteristic of polymeric films, and may be sticky or uncomfortable in contact with the skin of the user. Moreover, some methods of perforation may impart a certain degree of roughness to the surface of the film which further decreases comfort and consumer acceptance. In this regard, certain nonabsorbent but liquid permeable woven and nonwoven fabrics have superior softness and comfort as compared to apertured films.
It is accordingly an object of the present invention to provide a film having improved softness and hand with certain textile like properties. It is a further object of this invention to provide an apertured film having improved comfort and consumer acceptance when used as the liquid permeable cover on absorbent _3_ 1 3~2088 products. It is a yet further object of this invention to provide a method and apparatus for modifying apertured film in order to enhance the texture and physical properties thereof.
These and other objects of this invention will be apparent from the ensuing description and claims.

Summary In accordance with the preferred method of the present invention, apertured film for use as a cover material for absorbent products is subjected to a dual embossing process wherein the film is first macro embossed to expand the film out of the plane of the film in the thickness or Z-direction and impart a pronounced pattern to the surface of the film, and thereafter micro embossed with a finely engraved finish roll to flatten the structure into a thin, smooth film and impart a matte finish to the film while retaining the te~tile imprint of the macro embossing. The resulting product is a substantially two dimensional film having a smooth textured surface, low gloss and improved hand and softness.

~n an alternate embodiment, the order of embossing may be reversed wherein the apertured film is first embossed with the micro embossing roll followed by macro embossing. The 2S resulting product retains the micro embossed matte finish, but is highly expanded in the Z-direction following the macro embossing. The film accordingly has considerably greater loft or bulk than the macro-micro embossed film and may be preferred for certain end use applications.
The doubly embossed film retains its structural integrity and can be processed and assembled on absorbent products using conventional methods and equipment. The embossing reduces average hole size but increases hole size distribution which may be advantageous for certain applications. The processed _4_ 1 3220~8 film has improved hand, appears softer and less ~plastic" by subjective tests and is more comfortable in contact with the body.

DescriPtion of Drawinqs Figure 1 schematically illustrates the dual embossing process of the present invention.

Figures 2, 3 and 4 are enlarged plan views of various embossing patterns which may be utilized on a macro roll.

Figures 5, 6 and 7 are enlarged plan views of various embossing patterns which may be utilized on the micro embossing roll.
Figure 8 is an enlarged photograph of the surface of a preferred apertured film before embossing.

Figure 9 is an enlarged photograph of the surface of the same apertured film after embossing.

Descri~tion of the Invention In accordance with a preferred method of the present invention, a supply of apertured film, preferably in the form of rolled goods, is processed through a dual embossing station, substantially as illustrated in ~igure 1. Apertured film 10, such as that obtained by the process of U.S. Patent NoO 4,690,679, is fed from roll 11, over idler roll 12, to the first embossing station comprising macro embossing roll 13 and rubber coated anvil roll 14. Embossing roll 13 is a steel roll having a pronounced embossing pattern such as the textile-like patterns illustrated in Figures 2-4, where Figure 2 illustrates a cross-dash pattern, Figure 3 illustrates a basket-weave pattern, and Figure 4 illustrates a herringbone pattern. Anvil roll 14 is a steel roll having a rubber sleeve to provide a resilient backing surface for the embossing roll. Rolls 13 and 14 are individually driven at synchronized speeds to draw film 10 off roll 11. Embossing roll 13 is heated and forced against anvil roll 14 under controlled pressure, the optimum temperature and pressure being dependent upon the thickness and composition of the film and the embossing speed. Specific operating conditions are best determined e~perimentally for each particular film. If embossing conditions are too mild, i.e. temperature and/or pressure too low, the film will be insufficiently embossed and the desired deformation and pattern definition will not be obtained. If conditions are too severe, i.e. temperature and/or pressure too high, there will be excessive plastic flow resulting in extreme thinness and possibly holes in the land areas of the embossed film. In general, an embossing temperature greater than about 150F
will be used for polyolefin films.

While the macro embossing rolls preferably have a te~tile-like pattern, it will be understood that any macro embossing pattern comprising a multiplicity of projections in a regular or random pattern may be utilized according to the desired appearance of the final product. Each projection preferably has a face comprising a planer area, referred to herein as a "land~, and the projections may comprise two or more contiguous lands forming, for example, a chevron, right-angle or grid-type configuration. Since the film is stretched in the Z-direction during the embossing process, sufficient free area between lands must be provided to avoid overstressing and rupturing the film. While the minimum required free area will depend to some extent on the thic~ness and composition of the film, as well as on the height of the projections, in most cases the free area should comprise from 0.5 to 10 times the land area, and most preferably from 1 to 7 times the land area. Greater proportions of free area can be provided of course, but the -6- l 322088 embossing is less effective if the land area is substantially less than lO percent of the total surface area of the roll.

Apertured polymeric film for use as a cover material for absor~ent products generally has a thickness of from about l to 30 mils, and most preferably from about 3 to 10 mils. The pro~ections on the macro embossing roll preferably have a height of at least 0.3 mm, and most preferably from 0.5 to 1.0 mm. The projections are preferably tapered inwardly from the base to the land in order to reduce stress on the film during the embossing process. In this regard, the macro embossing rolls of the present invention conform to conventional practice for rolls intended to emboss plastic film.

Film leaving the macro embossing station is preferably passed through a chiller and around tensioning rolls before moving on to the micro embossing station. The chiller, illustrated schematically in Figure l, may consist of cooled rolls or a cool air stream and preferably reduces the film temperature to less than about 100F before the film contacts idler roll 16.
The cooled film passes around tensioning roll 17 and idler roll 18 before feeding into the micro embossing station comprising embossing roll 19 and anvil roll 20. Rolls l9 and 20 are indépendently driven by synchronous means which respond to the position of tensioning roll 17 in order to assure constant tension with uniform feed between the two embossing stations.
The micro embossing roll l9 is a steel roll engraved with a fine pattern such as that illustrated in Figures 5-7. Anvil roll 20 is a steel roll with a nylon sleeve which forms a firm backing surface for the micro embossing roll. Embossing roll l9 is heated and forced against the anvil roll at a temperature and pressure determined by the thickness and composition of the film, the nature of the pattern imparted by the macro embossing station, and the speed of the operation. Optimum processing conditions are best determined experimentally for each operation. 1 322088 The micro embossing rolls are provided with a finely engraved or otherwise suitably prepared surface to impart a matte finish to the film. As illustrated in Figure 5, one suitable embossing pattern comprises a series of parallel lines angled to the major axis of the roll with from about 2 to 20 lines per millimeter and each line cut to a depth of about 0.03 mm, this pattern being known in the art as a Schreiner pattern. Figure 6 illustrates a cross-cut pattern of intersecting lines at a 45 angle, and similar patterns of intersecting lines forming angles of 15 to 75 with the major axis of the roll may be used. Figure 7 illustrates a granular surface which may have regular or random projections and indentations formed by mechanical, chemical or electrochemical processing. In all these rolls, the desired effect is obtained if the surface texture of the roll is sufficient to impart a matte finish to the film during the micro embossing process.

Upon leaving the micro embossing station, the film passes through chiller 21, over idler roll 22, around tensioning roll 23, and onto windup 24. Chiller 21 preferably comprises refrigerated steel rolls to cool the film to about room temperature before the film is collected on windup 24.
The process of the present invention is further illustrated by the following example wherein the starting material was a coextruded apertured film comprising polyethylene and ethylene vinyl acetate as disclosed in U.S. Patent No. 4,690,679. The film had an average open area of about 42%, a thickness of about 4.5 mils, and a weight of about 1 oz. per sq. yard. The apertures had an average equivalent circular diameter of about 0.016 inches and an average center-to-center spacing of about 0.028 inches.

-8- 1 32208~
The apertured film was fed to the macro embossing station with the polyethylene side facing the steel embossing roll and the EVA side against the anvil roll. The speed of the macro embossing rolls was set at about 60 yds. per minute (ypm) and roll nip pressure was about 225 lbs. per linear inch (pli).
The embossing roll had a cross-dash pattern corresponding to that illustrated in Figure 2 with a projection height of 0.7 mm. The ratio of free area to land area was about 4:1. The roll was heated to a temperature of about 170F. The anvil roll was covered with 1/2 inch smooth rubber having a hardness value of about 60 on the Shore A scale. During operation, the anvil roll was not cooled and the surface temperature of this roll increased to about 115F.

After macro embossing, the film was cooled to room temperature and rewound. The film was subsequently processed through the micro embossing station at a speed of 95 ypm under a nip pressure of 500 pli. The micro embossing roll was engraved with the linear pattern illustrated in Figure 3 cut to a depth of 0.03 millimeters, and was heated to 170F. The anvil roll was covered with a smooth, 1 inch nylon sleeve having a hardness of about 100 on the Shore A scale. ~uring operation, the anvil roll was not cooled and reached a surface temperature of about 97F. The resulting film was subsequently cooled to room temperature and collected on a rewind roll.

The apertured film which formed the starting material in the above example is illustrated in Figure 8 which is a photograph of the film surface enlarged 5x. The product resulting from the above example is illustrated in Figure 9 which is also a surface photograph illustrated 5x. The change in film te~ture which is readily visible in the photographs translates into a significant improvement in hand, appearance, softness, comfort against the skin, and consumer acceptance when used as a cover material for absorbent products.

The preceding description and examples are directed to a preferred embodiment of the present invention, and many variations therein are possible and within the scope of the invention. For example, a variety of embossing patterns may be utilized on the macro embossing roll other than those illustrated in Figures 2-4. Any embossing roll which imparts a pronounced pattern to the film without rupturing the film can be used with good results, the important consideration being that the macro embossing process should expand the film at least about 2x in the Z-direction and impart a distinct and visually pleasing pattern.

The micro embossing roll may likewise comprise patterns other than those illustrated in Figure 5-7, the important consideration being that the micro embossing roll has a pattern which imparts a low sheen matte finish to the plastic film, thereby enhancing its smoothness and visual appearance. In a less preferred embodiment, micro embossing roll 19 may be a smooth roll, although this results in a higher gloss and diminished textile-like appearance in the finished product.

These and other variations will be apparent to those skilled in the art, and the present invention is accordingly not limited except by the claims appended hereto.

Claims (34)

1. A process for imparting surface texture and smoothness to an apertured polymeric film comprising:

a. macro embossing an apertured film having a unit thickness in the Z-direction at an elevated temperature and pressure to expand the film in the Z-direction and impart a pronounced pattern to said film, and b. micro embossing said macro embossed film to reduce the thickness of the film in the Z-direction to substantially its original unit thickness while retaining the macro embossed pattern therein.
2. The process of claim 1 wherein said film is expanded in the Z-direction to at least twice its original unit thickness by said macro embossing.
3. A process of claim 1 wherein said apertured film is selected from the group consisting of polypropylene, polyethylene and bicomponent polyethylene/ethylene vinyl acetate.
4. A process of claim 1 wherein said apertured film has an original unit thickness of from 1 to about 30 mils.
5. A process of claim 1 wherein said apertured film has an original unit thickness of from about 3 to 10 mils.
6. A process of claim 1 wherein said film comprises polyethylene and said macro embossing temperature is greater than about 150°F.
7. A process of claim 6 wherein said film is cooled to less than about 100°F after macro embossing and before micro embossing.
8. A process of claim 6 wherein said film is coextruded polyethylene/ethylene vinyl acetate having a thickness of about 4.5 mils and an average open area of about 40%.
9. The process of claim 1 wherein said pronounced pattern is a textile-like pattern selected from the group consisting of cross-dash, herringbone and basket weave patterns.
10. The process of claim 1 wherein said micro embossing roll comprises an engraved linear pattern.
11. A process for imparting surface texture and softness to an apertured polymeric film comprising a. micro embossing said film at an elevated temperature and pressure with a roll having a surface texture sufficient to impart a low reflectance matte finish surface to said film, and b. macro embossing said micro embossed film to expand the film in the Z-direction and impart a pronounced pattern to said film while retaining the micro embossed matte finish thereon.
12. The process of claim 11 wherein said film is expanded in the Z-direction to at least twice its original thickness by said macro embossing.
13. A process of claim 11 wherein said apertured film is selected from the group consisting of polypropylene, polyethylene and bicomponent polyethylene/ethylene vinyl acetate.
14. A process of claim 11 wherein said apertured film has an original thickness of from 1 to about 30 mils.
15. A process of claim 11 wherein said apertured film has an original thickness of from about: 3 to 10 mils.
16. A process of claim 11 wherein said film comprises polyethylene and said micro and macro embossing temperatures are greater than about 150°F.
17. A process of claim 16 wherein said film is cooled to less than about 100°F after micro embossing and before macro embossing.
18. A process of claim 11 wherein said film is coextruded polyethylene/ethylene vinyl acetate having a thickness of about 4.5 mils and an average open area of about 40%.
19. The process of claim 11 wherein said pronounced pattern is a textile-like pattern selected from the group consisting of cross-dash, herringbone and basket weave patterns.
20. The process of claim 11 wherein said micro embossing roll comprises an engraved linear pattern.
21. Apparatus for imparting surface texture and smoothness to apertured polymeric films comprising:

a. macro embossing means comprising a steel embossing roll and a resilient anvil roll, the surface of said macro embossing roll being provided with a prominent pattern of raised projections;

b. micro embossing means comprising a steel embossing roll and a nonresilient anvil roll, the surface of said micro embossing roll being provided with a surface texture sufficient to impart a matte finish to said polymeric film, and c. means for passing said apertured polymeric film through said micro and macro embossing means and for thereafter collecting said film.
22. The apparatus of claim 21 wherein said projections on said macro embossing roll have a height of from about 0.3 to 1.0 millimeters.
23. The apparatus of claim 22 wherein said projections on said macro embossing roll are in a textile-like cross-dash, basket weave or herringbone pattern.
24. The apparatus of claim 21 wherein said resilient anvil roll has a rubber surface and a Shore A hardness of about 60 degrees.
25. The apparatus of claim 21 wherein said nonresilient anvil has a nylon surface with a Shore A hardness of about 100 degrees.
26. The apparatus of claim 21 wherein the surface of said micro embossing roll is engraved in a linear pattern.
27. The apparatus of claim 26 wherein said linear pattern comprises a series of closely spaced parallel lines at an angle of from about 15° to 75° to the major axis of the roll.
28. The apparatus of claim 27 wherein said parallel lines are spaced apart about 0.1 millimeter and have a depth of about 0.03 millimeter.
29. The apparatus of claim 27 wherein said linear pattern comprises a first series of closely spaced parallel lines intersected at an angle by a second series of closely spaced parallel lines.
30. The apparatus of claim 21 further comprising means for cooling said film after said micro embossing and before said wind-up.
31. The apparatus of claim 21 further comprising means for cooling said film intermediate said macro and said micro embossing means.
32. The apparatus of claim 21 wherein the free area between said projections on said macro embossing roll is from 0.5 to about 10 times the land surface area of said projections.
33. An apertured polymeric film produced by the process of claim 1.
34. An apertured polymeric film produced by the process of claim 11.
CA000576297A 1987-09-03 1988-09-01 Method and apparatus for preparing textured apertured film Expired - Fee Related CA1322088C (en)

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US4259286A (en) * 1979-05-04 1981-03-31 The Procter & Gamble Company Method and apparatus for texturing a thermoplastic film
US4463045A (en) * 1981-03-02 1984-07-31 The Procter & Gamble Company Macroscopically expanded three-dimensional plastic web exhibiting non-glossy visible surface and cloth-like tactile impression
US4690679A (en) * 1986-03-14 1987-09-01 Johnson & Johnson Coextruded apertured film sanitary napkin cover

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Publication number Publication date
JPH01145132A (en) 1989-06-07
AU2182388A (en) 1989-03-09
EP0313766A3 (en) 1990-05-02
ATE102447T1 (en) 1994-03-15
MY104104A (en) 1993-12-31
DE3888283T2 (en) 1994-10-06
ES2049739T3 (en) 1994-05-01
PT88418B (en) 1994-04-29
PT88418A (en) 1989-07-31
US4859519A (en) 1989-08-22
PH26532A (en) 1992-08-07
DE3888283D1 (en) 1994-04-14
AU606204B2 (en) 1991-01-31
EP0313766A2 (en) 1989-05-03
EP0313766B1 (en) 1994-03-09
JP2577784B2 (en) 1997-02-05
BR8804569A (en) 1989-04-11
ZA886559B (en) 1990-05-30
AR245400A1 (en) 1994-01-31
NZ226036A (en) 1990-07-26

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